Method of producing fabric

ABSTRACT

The method of producing pile fabric which includes by definition rugs, carpets and the like, by looping the pile in spanning relation between two backings or strata and cutting the loops between such backing, thereby producing loop-free pile fabrics in which all the loops are evenly cut.

United States Patent [191 Forstmann i Sept. 4, 1973 METHOD OF PRODUCING FABRIC [76] Inventor: Gunther Forstmitnn, 47 Hewes St., Port Jefferson Station, NY. 11776 [22] Filed: Mar. 22, 1972 [21] Appl. No.: 236,866

[52] U.S. Cl. 112/266, 66/85 A, 112/79 R [51] Int. Cl. D05c 15/00 [58] Field of Search 112/2, 9, 78, 7 9,

l12/79.5,127,155, 163, 165, 166, 197, 266, 410; 66/85 A,19l, 194; 161/62; 156/72, 148,

[56] References Cited UNITED STATES PATENTS 2,979,803 4/1961 Keen 161/62 3,013,511 12/1961 Nebich ..L 112/79 R 3,229,652 l/1966 Ridyard et al. ll2/266 X 3,583,346 6/1971 Bloch 112/410 FOREIGN PATENTS 01R APPLICATIONS 1,269,761 6/1968 Germany 66/85 A 1,254,185 l/l961 France 112/79 R Primary ExaminerWerner H. Schroeder Att0meyBauer & Amer [57] ABSTRACT The method of producing pile fabric which includes by definition rugs, carpets and the like, by looping the pile in spanning relation between two backings or strata and cutting the loops between such backing, thereby producing loop-free pile fabrics in which all the loops are evenly cut.

3 Claims, 3 Drawing Figures s f t, k r 30 PATENTEDSEP 4 ms FIG! FIGZ

METHOD OF PRODUCING FABRIC The present invention relates generally to improvements in production methods of providing pile fabrics, and more particularly to a method of producing pile fabrics which is an improvement in its method aspects per se, such as reduced handling, increased production, and the like, and which also yields a pile fabric having noteworthy product aspects.

As generally understood, a pile surface on a tufted fabric is produced by the removal of the tops (i.e. closed ends or loop portions) of pile loops tufted in a backing fabric. Care must be exercised to avoid inadvertently missing any loops, and while this can be achieved in any number of ways, it adds to the expense of producing the pile fabric.

Broadly, it is an object of the present invention to provide a method of producing pile fabrics in the practice of which the severing of the pile loops is facilitated without additional cost, and in fact, production is in creased. Specifically, it is an object to provide a production method in which each pile loop is cut medially of its ends, thereby totally obviating the possibility that the top thereof will be missed during shearing.

A method of converting tufted pile loops into a pile surface demonstrating objects and advantages of the present invention contemplates the depositing or tufting of said pile loops through two backing fabrics which, when subsequently separated, effectively exposes the medial region of the loops, i.e. the region extending between the fabrics, to the severing action of a cutting implement that is passed between the fabrics.

The above brief description, as well as further objects, features and advantages of the present invention, will be more fully appreciated by reference to the following detailed description of a pile fabric in various progressive stages of production, as illustrated in the accompanying drawings, wherein:

FIG. 1 is a side elevational view illustrating the pile fabrics at an early stage of their manufacture;

FIG. 2 illustrates the manner of converting yarn connecting two backing fabrics into a pile surface for each; and

FIG. 3 is a partial perspective view diagramatically illustrating the arrangement of the yarn in the backing fabrics preparatory to the conversion of the yarn into pile surfaces.

Reference should be made to FIG. 2, and more particularly to the right-hand portion thereof, wherein backing fabrics 10 and 12 are illustrated with severed, delaminated segments or lengths of yarn, individually and collectively designated 14, extending therefrom and serving, in a well-understood manner, as a pile surface for each of the backing fabrics l and 12. Although the product aspects of fabrics having the just described pile surfaces are well known, the within method of producing the fabrics and 12 with pile 14, as described in detail herein, represents a significant advance over known methods. Specifically, typical of known methods is the method described in US. Pat. No. 3,152,381 in which a single backing fabric is tufted with loops or yarn which are subsequently converted into a surface pile.

Among other significant differences, the within method of producing pile fabrics contemplates, as illustrated in FIGS. 1 and 3, the use of a plurality and at least two backing strata or fabrics, as for example fabrics I0 and 12 already noted, which are placed in overlying, face-to-face-relation. Next, yarn having the requisite physical characteristics suitable for producing the pile surface in terms of twist, denier, and numbers of fibers or filaments, such as previously noted yarn 14, is tufted in opposite directions through the backing strata fabrics l0 and 12. Specifically, as shown in FIG. 1, yarn 14, as a result of the tufting operation, takes the specific form of loops l6 extendling in one direction through the fabrics, and loops 18 similarly extending through the fabrics but in the opposite direction. Preferrably, the loops l6 and 18 are disposed in alternate locations relative to each other (FIG. I) and in alternate rows (FIG. 3).

The tufting of the pile loops 16 and 18 may be accomplished using conventional tufting machines tufting from top and bottom. Moreover, the extent or distance 20 that the pile loops, as for example loops 16, extend beyond the supporting backing fabrics 10, I2 is a function of the distance of the tufting stroke of the tufting machine and will be understood to be selected in accordance with the desired height of the ultimate pile surface 14.

After placement, by tufting, of the pile loops l6 and 18 throughout the face-to-face superposed backing fabrics 10 and 12, the method hereof contemplates, as illustrated in FIG. 2, the separating movement of the backing fabrics l0 and 12 into a relatively spaced clearance position from each other. This results in the loops 16 and 18 being drawn into a taut condition in spanning relation between the fabrics 10 and 12. This separation or movement of the backing fabrics into a clearance position serves two purposes: First, it defines a yarn cutting zone 22 between the fabrics. Second, it draws out the pile loops l6 and 18 into uniform lengths 24 between the two facing surfaces of the fabrics I0 and 12. In this connectionfeacb yarn length 24 is the distance measured from the needle holes through which the beginning and ends of a pile loop are projected through one backing fabric to the common needle hole, designated 26 in FIG. 2, through which the looping portion 28 of each respective loop is projected through in the other backing fabric.

To prevent inadvertent disengagement of a loop portion 28 from a cooperating needle hole 26, it is necessary to maintain the space or distance 24 to a value which is less than the length of the pile loops 16 and 18. Additionally, the bulk of the knot produced by the loop which is presented by the reversal in direction of the looping portions 28 offers resistance to inadvertent withdrawal movement through the comparatively small needle hole 26. Still further, it has been found that, in addition to adding to the density of the ultimate plush or pile surface 14, the tufting of pile loops 16 and 18 in opposite directions through the backing fabrics 10 and 12, as described herein, provides looping portions 28 on the outside surfaces of both of the backing fabrics l0 and 12 and that this condition, in an obvious manner, contributes to providing a resistance to excessive separation or clearance movement in the backing fabrics l0 and 12.

As a final step, the method hereof contemplates severing the spanning yarn portions 16 and 18 at a selected location within the cutting zone 22. The severing of the yarn 14 may be done using a rotary cutting implement, or any other appropriate means. As illustrated in exemplary fashion in FIG. 2, cutting of the spanning yarn l4 may be done along a plane 30 which is parallel to and, although shown equidistant from the two facing surfaces of the backing fabrics l and 12, the distance may be predeterminately controlled. Separation and severing or cutting of the yarn 14, also referred to as splitting, may be accomplished by the use of conventional leather splitting machines.

From the foregoing, it should be readily appreciated that upon severing the spanning yarn 14, the two backing fabrics l0 and 12 are disconnected from each other so that the length 14 of the severed yarn in each cooperate to form and effectively serve as a pile surface on each of the fabrics l0 and 12. By predeterminately controlling the location, spacing and relative placement and positioning of the tufts, it is also possible to pro-.

duce predetermined pile designs and patterns in each of the strata of fabric after the same are cut or severed from each other.

Among other advantages, the method of producing pile fabrics as just described yields a pile 14 of maximum height for the height of pile loops utilized since it obviates any need to cut off the tops 28 of the pile loops as required in prior art methods. It also yields two loopfree pile fabrics for the same handling that is substantially required to produce a single pile fabric according to prior art methods. Still further, it presents the yarn in an advantageous taut condition for cutting whereas it was not uncommon, according to prior art practice, for many of the tops of the loops to be missed during shearing unless considerable care was exercised to hold or support the loops in elevated condition preparatory to cutting or shearing thereof.

A latitude of modification, change and substitution is intended in the foregoing disclosure, and in some instances some features of the invention will be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the spirit and scope of the invention herein.

Among other advantages, the method of producing pile fabrics as just described yields a pile 14 of maximum height for the height of pile loops utilized since it obviates any need to cut off the tops 28 of the pile loops as required in prior art methods. It also yields two loopfree pile fabrics for the same handling that is substantially required to produce a single pile fabric according to the prior art methods. Still further, it presents the yarn in an advantageous taut condition for cutting whereas it was not uncommon, according to prior art practice, for many of the tops of the loops to be missed during shearing unless considerable care was exercised to hold or support the loops in elevated condition preparatory to cutting or shearing thereof.

A latitude of modification, change and substitution is intended in the foregoing disclosure, and in some instances some features of the invention will be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the spirit and scope of the invention herein.

What is claimed is:

l. The method of making pile fabrics by tufting yarn through at least two fabrics by tufting machines disposed on opposite sides of such fabrics comprising placing the at least two fabrics in face-to-face relation, tufting yarn by each of the oppositely disposed tufting machines such that the tufting yarn passes completely through each of the two fabrics from opposite sides thereof with each tuft of yarn having a portion thereof forming a loop extending through and projecting beyond the fabric most remote from the initiating tufting machine and having a backing portion extending along the outer surface of the fabric facing the initiating tufting machine.

separating the oppositely tufted together fabrics from each other along the tuft loops extending therethrough to a desired relative spacing such that the end of each loop forms an enlarged resistance to the inadvertent withdrawal of the loop back through the most remote fabric,

and severing the tufts between the spaced fabrics such that each severed fabric has a backing portion of a tuft initiated by a tufting machine on its own side and the end of a loop of a tuft initiated by a tufting machine on the opposite side.

2. The method of producing pile fabrics as defined in claim 1 wherein the loops of said yarn tufted in opposite directions are alternately positioned relative to each other.

3. The method of producing pile fabrics as defined in claim 1 wherein said tufted loops of yarn are arranged in a plurality of parallel rows throughout said backing fabrics. 

1. The method of making pile fabrics by tufting yarn through at least two fabrics by tufting machines disposed on opposite sides of such fabrics comprising placing the at least two fabrics in face-to-face relation, tufting yarn by each of the oppositely disposed tufting machines such that the tufting yarn passes completely through each of the two fabrics from opposite sides thereof with each tuft of yarn having a portion thereof forming a loop extending through and projecting beyond the fabric most remote from the initiating tufting machine and having a backing portion extending along the outer surface of the fabric facing the initiating tufting machine. separating the oppositely tufted together fabrics from each other along the tuft loops extending therethrough to a desired relative spacing such that the end of each loop forms an enlarged resistance to the inadvertent withdrawal of the loop back through the most remote fabric, and severing the tufts between the spaced fabrics such that each severed fabric has a backing portIon of a tuft initiated by a tufting machine on its own side and the end of a loop of a tuft initiated by a tufting machine on the opposite side.
 2. The method of producing pile fabrics as defined in claim 1 wherein the loops of said yarn tufted in opposite directions are alternately positioned relative to each other.
 3. The method of producing pile fabrics as defined in claim 1 wherein said tufted loops of yarn are arranged in a plurality of parallel rows throughout said backing fabrics. 